Lewmar OCEAN & EVO Electric/Hydraulic Winches

Transcription

1 Lewmar OCEAN & EVO Electric/Hydraulic Winches B2303 Issue 12 Ocean Winch size Evo Winch size GB Owners Installations, Operation & servicing manual

2 GB 1. Introduction Dear Customer, Thank you for choosing Lewmar. Lewmar products are world renowned for their quality, technical innovation and proven performance. With a Lewmar product you will be provided with many years of outstanding service. Product support Lewmar products are supported by a worldwide network of distributors and Authorised Service Representatives. If you encounter any difficulties with this product, please contact your national distributor, or your local Lewmar dealer. Details are available at CE Approvals For CE approval certificates contact Lewmar. Important information about this manual Throughout this manual, you will see safety and product damage warnings. You must follow these warnings carefully to avoid possible injury or damage. The type of warnings, what they look like, and how they are used in this manual are explained as follows:. WARNING! This is a warning against anything which may cause injury to people if the warning is ignored. You are informed about what you must or must not do in order to reduce the risk of injury to yourself and others. SAFETY SYMBOL When you see the safety symbol it means: Do not... ; Do not do this ; or Do not let this happen. 2

3 2. Safety Notice IMPORTANT: Read these notes before continuing. WARNING! 2.1 Winches general Please ensure that you thoroughly understand the operation and safety requirements of the winch before commencing the installation. Only persons who are completely familiar with the controls and those who have been fully made aware of the correct use of the winch should be allowed to use it. If there is any doubt of how to install or operate this unit please seek advice from a suitably qualified engineer. Winches used incorrectly could cause harm to equipment or crew. Winches should be used with care and treated with respect. Sailing, like many other sports can be hazardous. Even the correct selection, maintenance and use of proper equipment cannot eliminate the potential for danger, serious injury or death. Lewmar winches are designed and supplied for line control in marine applications and are to be used in conjunction with appropriate clutches, cleats and other manual controls and stoppers. It is the unavoidable responsibility of the owner or master or other responsible party to assess the risk of any operation on the vessel. Under no circumstances should any self tailing winch be used in self tailing mode for any lifting operation; rather suitable and adequate manual tailing should be arranged with proper means of manually cleating or stopping the hoist. Every winch should be installed with adequate means of manually cleating or stopping the loaded ropes. 2.2 Fitting This equipment must be installed and operated in accordance with the instructions contained in this manual. Failure to do so could result in poor product performance, personal injury and/or damage to your boat. Consult the boat manufacturer if you have any doubt about the strength or suitability of the mounting location. 2.3 Electrical Make sure you have switched off the power before you start installing this product. If in doubt about installing electrical equipment please seek advice from a suitably qualified electrical engineer. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 3

4 GB 3. Installation 3.1 Electric conversion kit OCEAN A KIT B C EVO A KIT B C Ocean Wavespring manual winches manufactured from 1992 and EVO manual winches can be converted to electric powered operation with a Lewmar conversion kit consisting of the following: Centre stem (A) and a power drive base (B). Then specify a suitable Lewmar motor/gearbox (C) to form the basic electric winch deck unit conversion. 3.2 Preparing manual winch for electric conversion IMPORTANT: Check existing winch location is suitable for positioning motor/gearbox, see section 3.4. Remove the winch from the deck, replace centre stem with supplied kit centre stem. Reassemble winch, fix power drive base to the centre stem and fit motor/gearbox as instructed in this manual. 3.3 Above deck preparation electric/hydraulic winch IMPORTANT: Always keep in mind the space available below deck for the motor/gearbox or hydraulic drive unit. Plan location carefully before drilling any holes and allow for the following: degree rotation of manual operating handle. 2. Lewmar recommend that the rope enters onto the drum at an angle of 5 to 10 to the base axis of the winch. To achieve this angle it may be necessary to use a base wedge when installing the winch to to -10 4

5 3. It is essential that the winch is fixed to an even surface for maximum performance. 4. If practical, for best performance, the winch should be installed so that the output gear (A) is situated in the optimum position in relation to the load (B) and sheet line entry (C). 5. Winches Once position of winch is established, mark position of centre stem and drill Ø64mm hole. Strip winch (section 3.5) place base plate on deck then mark through mounting bolt holes, remove and drill to size of bolts. Winches Remove the winch drum. Access to mounting holes is available through holes in the base of the centre stem. Mark hole positions and drill as necessary C B A 3.4 Below deck preparation IMPORTANT: The positioning of the motor/gearbox or hydraulic drive unit must be checked prior to cutting for deck/hull and bulkhead clearance. 1. The motor/gearbox can be rotated in 90 degree steps. 2. The motor rotation is factory set for fitting to drive shaft as shown Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 5

6 GB 3. If the motor/gearbox is fitted the opposite way round it will produce the following problems: On a single speed winch it will not operate and make a clicking noise. Remove motor/gearbox and refit the opposite way round. On a 2 or 3 speed winch it will dramatically reduce performance. Contact Lewmar for correct fitting of electrical connections to rectify this situation or refit the motor/gearbox the opposite way round. 4. Correct spindle rotation when fitted and operated. Check clearance below deck and accessibility then position the deck switches near and in view of the winch. Use template as a guide to cut/drill hole, fit switch and seal. Once you have selected the ideal position for winch, motor/gearbox and controls, double check everything and only then drill holes in the deck OCEAN EVO 1st 2nd 3rd Fitting an electric/hydraulic winch WARNING! Isolate the winch using circuit breaker/isolator. NOTE: Illustrations based on Model 50 Ocean winch unless stated otherwise. For winch models over 65 just removing the drum gives access to fixing bolt holes. Place the winch in position to ensure correct fit once the holes have been drilled/cut. 1. Unscrew the top cap anti-clockwise and remove. 2. OCEAN 40- Remove feeder arm and collets. OCEAN Remove feeder arm. 3. EVO - Rotate the drum until the cutout in the upper crown is opposite the collets. 6

7 EVO OCEAN EVO Lift off drum. Remember to take care in re-fitting the drum washer with bevel on underside. 5. Remove all screws holding centre stem to base. Using a flat bladed screwdriver in the drainage slots, lever off centre stem assembly clear of the two dowel pins. NOTE: For manual to electric winch conversion, replace centre stem with kit supplied unit Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 7

8 GB 6. Take care to hold the gear stack in position as shown. Keep pawls and pawl springs in place while rebuilding/ placing the centre stem onto the base. NOTE: If pawl gear falls away, ensure shoulder face is down on re-assembly. Take notes of gear and other component positions if replacing the original stem with the conversion kit stem ready for reassembly OCEAN 40~65 EVO 40~ Remove the base plate cover. Lift the base and bed down with a light coating of sealing compound to prevent leaks. Avoid using excessive sealant. DO NOT use a permanent adhesive/sealant, eg Consult the fastening guide for bolt type and length. Bolt the base plate to the deck ensuring that all fastening heads are countersunk then replace base plate cover. NOTE: If using silicone or other rubbery type sealant, it is advisable to allow curing of the sealant before final tightening of the mounting nuts. 9. Refit the centre stem assembly, taking care to hold the gear stack in position as before. Rotating the gears will facilitate re-engagement of the pawls and ratchet tracks. Replace the drum, collets and feeder arm in correct position and screw on the top cap

9 3.6 Fastenings NOTE: Deck fastenings are not supplied. 1. Fix the winch to the deck using CSK Head, stainless steel washers and locknuts. Use the table below to calculate the correct bolt length for your deck thickness OCEAN EVO (x) mm (x) inch (Min.) (Min.) Nm /4 5 x M6 (1/4 ) /16 5 x M8 (5/16 ) 21 50/ /16 6 x M8 (5/16 ) /16 5 x M10 (3/8 ) /2 5 x M10 (3/8 ) /4 8 x M10 (3/8 ) If a thick deck or increased motor/gearbox distance from deck demands a greater T dimension (see section 8). Optional extension kits are available to special order, please contact your nearest Lewmar office. NOTE: Optional Lewmar FAST FIT studs screw directly into the base of the winch without having to remove the drum. Contact Lewmar for more details T 3.7 Electric winch motor/gearbox coupling Winches These winches require the base motor coupling and shim to be fitted. Apply Loctite threadlock to coupling bolts (# 15), insert isolation shim and secure to winch base plate. Assemble coupling bolts and washers, apply Loctite threadlock and secure to 21Nm. Lightly coat the drive shaft with grease. Ensure the drive key is in place. Select the most suitable position and slide motor/gearbox into position, assemble bolts and washers, apply Loctite threadlock and secure to 43Nm. #15 B0678 x Nm LOCTITE Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 9

10 GB Winches Assemble coupling motor bolts and washers apply Loctite threadlock and secure to 43Nm. Lightly coat the drive shaft with grease. Ensure the drive key is in place. Select the most suitable position and slide motor/gearbox into position, assemble bolts and washers, apply Loctite threadlock and secure to 43Nm. 43 Nm LOCTITE Hydraulic winch coupling Winches These winches require the base motor coupling and shim to be fitted. Apply Loctite threadlock to coupling bolts (# 15), insert isolation shim and secure to winch base plate. Assemble coupling bolts and washers, apply Loctite threadlock and secure to 21Nm. Hydraulic drive unit case drains DO NOT need to be fitted. Lightly coat the motor splined input shaft with grease and slide motor into position, assemble bolts and washers, apply Loctite threadlock and secure to 43Nm. #15 B0678 x 5 21 Nm LOCTITE 43 Nm LOCTITE Winches Lightly coat the motor input shaft with grease and slide motor into position. Assemble coupling bolts and washers, apply Loctite threadlock and secure to 43Nm. NOTE: See section 5 for hydraulic connection specifications Nm LOCTITE 10

11 4. Electrical Wiring 4.1 Electric cable selection The cable table gives recommended cable sizes based on total length of cable required, from the battery, following the route of the cables. Lewmar recommends to source and install cable that meets the requirements of the standards and regulations relevant to the installation and codes of practice. DO NOT confuse cable Length with the length of the vessel! Winch performance is directly related to cable size and length. The cable sizes are calculated so that the maximum overall voltage drop do not exceed10% over the whole cable installation. WARNING! All electrical work must be carried out with the power OFF. Isolate the winch using circuit breaker/isolator. CABLE SIZE 12V DC CABLE SIZE 24V DC TOTAL CABLE DISTANCE 50 mm2 (1/0 AWG) 25 mm2 (3 AWG) up to 7 m (23 ft) 70 mm2 (2/0 AWG) 35 mm2 (2 AWG) 7-10 m (23-33 ft) 70 mm2 (2/0 AWG) 50 mm2 (1/0 AWG) m (33-49 ft) 95 mm2 (3/0 AWG) m (49-66 ft) 4.2 Wiring Plan the installation to suit the controls and give the operator a full view of the winch. The wiring system should be of the fully insulated type, which avoids possible electrolytic corrosion problems. We recommend the use of type III stranded, tinned copper wire with copper crimp terminals. Most modern installations are negative return (negative ground) but polarity should be checked. Overload protection, in the form of the circuit breaker/fuse (not supplied), must be built into the winch wiring circuit. NOTE: The circuit breaker should be positioned close to the battery in a dry, readily accessible place. The breaker must be manually reset should an overload occur that causes it to trip to the off position. WARNING! If you are not sure you understand these guidelines, seek professional help. Ensure that the installation complies with USCG, ABYC, NMMA or other local regulations. 4.3 Control switch installation Follow the mounting instructions supplied with the switch. 4.4 Electric motor terminal connections When wiring Lewmar electric motor into the ship s electrical system the following caution must be taken. When tightening the front nut hold the back nut with a separate wrench to make sure the back nut does not turn. If the back nut turns, serious damage will occur, voiding Lewmar s warranty on the electric motor. DO NOT over tighten electric motor terminal nuts. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 11

12 GB 4.5 Typical electrical layout NOTE: This is not a wiring diagram. 1. Position the circuit breaker close to the battery. 2. Route 2 cables from battery to the control box. 3. Attach motor cables to control box using recommended cable sizes. 4. Position the control box near the winch (± 1 metre) in a dry area for watertight security and accessible for maintenance. 5. Position deck switches in view of the winch. Route wire and attach to control box Type E - 40/46/48 + EVO 50 electric 12/24V This simple installation of a power drive unit, motor and switch gear controls the winch by a single direction contactor, which can be a contactor housed in a waterproof box or a stand alone encased unit. The motor thermal trip is connected to monitor motor temperature. Manual override facility is still available for backup, or as a means of experiencing traditional sailing. Two plus one speed comes as standard control which gives two speed manual drive (handle) plus one speed electric drive. 4.7 Type ELS electric 12/24V This Electric Load Sensing installation controls the winch by Lewmar s unique Overload Protection Control Box, this allows the winch to be operated up to a set current relative to maximum load. 4.8 Type ELS EVO 80 electric 12/24V This installation controls the winch by Lewmar s unique Overload Protection & Autoshift Control Box. This allows the winch to be started in 1st and if reaches the Safe Working Load, for the winch size and gear, will automatically shift the winch into 2nd gear for complete load control. In the case of a 3 speed winch the switch must be re-selected to achieve 3rd gear. 4.9 Electric deck switches For the latest information and list of electric deck switches visit: 12

13 4.10 Wiring diagram Switch wire thickness: 1.5 mm2 (16 AWG) Battery 12/24VDC Battery Isolator Circuit Breaker (see manual) D2 A2 2 D1 Fuse 3A Thermal Switch Contactor 12V V Thermal Switch Fuse 3A Contactor Box 12V V D2 A2 D1 Thermal Switch A1 F2 Thermal Switch A2 F1 3 Fused 3A EVO WINCH ELS CONTROL BOX Cable link - Use same size & type as main cables, if not fitted. 3 Fused 3A D2 A2 D EVO WINCH ELS CONTROL BOX 3 4 Electric Deck Switch MOTOR + BATT EVO WINCH E SERIES CONTACTOR ONLY BATT + MOTOR EVO WINCH E SERIES CONTACTOR BOX Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 13

14 GB 4.11 Wiring diagram EVO 70/80 Switch wire thickness: 1.5 mm2 (16 AWG) 68/77 + EVO 70/80 WINCH ELS CONTROL BOX 14

15 5- Hydraulic System 5.1 Installation NOTE: Hydraulic system installation is NOT covered in this publication. Lewmar hydraulic winches have been designed for ease of installation and follow a straight forward hydraulic and mechanical installation procedure. Fig shows typical hydraulic circuit for a winch with the Lewmar Commander Power System or equivalent. The purpose of this manual is to provide the reader with sufficient information to install and operate a hydraulic winch. It assumes the reader will be familiar with sailing craft, marine hydraulics, mechanical installation and safety requirements. If in any doubt consult a qualified marine engineer. Fig WARNING! The installation of hydraulic systems requires a high level of cleanliness. The ingress of dirt will dangerously impair the safe operation of the system and cause premature wear of hydraulic components. 5.2 Hose types NOTE: Hoses and connectors are not supplied. For reliable operation and safety it is essential to use reinforced braid hose for connecting to the motor A and B ports which conforms to SAE100R7 or ISO D1S3949 safety requirements. The recommended hose sizes are: Up to 15m (50ft) 12mm (1/2 ) Over 15m (50ft) 16mm (5/8 ) Safe working pressure : see performance graphs section 6. Minimum recommended bend radius 150mm (6 ) 5.3 Hydraulic drive unit NOTE: Refer to your installed hydraulic system manual for hydraulic drives. This table refers to Lewmar Commander system port connections only. The Lewmar hydraulic motor ports are: A & B ports 1/2 BSP. OCEAN EVO Motor Speeds Port A Port B A B A B 50-1 A B A B 58-1 A B A B A B A B A B A B Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 15

16 GB 6- Operation 6.1 Powered winch overview WARNING! Always remove handle when not in use. WARNING! Isolate the winch using circuit breaker/isolator when not in use. Electric and Hydraulic EVO These are single speed powered winches and manual 2 speed, these winches employ an override ratchet gearing for safety when winching manually. To operate winch press the deck switch. Electric EVO and Hydraulic EVO These are 2 or 3 speed powered and manually operated, they will not drive electrically while the winch lock-in handle is in the drive socket. 2 Speed Winch operation Autoshift (Standard) To engage winch press the deck switch, first gear will engage and centre spindle will rotate counterclockwise. When load increases it will automatically switch to the next gear. Optional 2nd gear switch To engage winch in first gear press the deck switch, centre spindle will rotate counter-clockwise. To engage second gear press second gear deck switch, when engaged the centre spindle rotates clockwise. 3 Speed winch operation Autoshift (Standard) Push winch base button in. To engage winch, press the deck switch, first gear will engage and centre spindle will rotate clockwise. When load increases it will automatically switch to 2nd gear. The winch base button will disengage and centre spindle will turn counter-clockwise. To engage third gear press the deck switch again, when engaged the central spindle will rotate clockwise. Optional 2nd gear switch Push winch base button in. To engage winch in first gear press the 1st gear deck switch, centre spindle will rotate clockwise. To engage 2nd gear press the 2nd gear deck switch, when engaged centre spindle rotates counterclockwise and the winch base button will disengage. To engage third gear press the 1st gear deck switch again, when engaged the central spindle will rotate clockwise. 16

17 6.2 Adjusting self tailers To adjust the position of the feeder arm, remove top cap and feeder arm. OCEAN EVO EVO OCEAN - Unscrew the top cap anti-clockwise and remove feeder arm. 2. EVO - Unscrew the top cap anti-clockwise and remove feeder arm. Ensure O ring remains in top cap groove. 3. Rotate stripper ring to required position. Adjust the feeder arm so that the rope tails into a secure area away from the incoming line. EVO Replace feeder arm and top cap. 5. The turn leading from the drum must be passed across the stripper mechanism as shown, and placed correctly into the spring jaws. There must be a minimum of three turns of rope on the drum. Release the rope from the jaw set with care as load will be present, ease the line away with care, then remove from the drum. The jaws are designed to accept a range of rope diameters. The winch should only be used with ropes of the sizes recommended. Use the winch handle or power switch to operate the winch. WARNING! Always remove handle when not in use. WARNING! Never hold the incoming rope to the winch while the winch is operated. Only control the rope leaving the winch. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 17

18 GB 6.3 Electric performance The following graphs show line speed and amperage draw relative to the load applied. Each control box will cut out at a set current relative to maximum load. (A) Line speed (m/min) (B) Current (Amp) (C) Load (kg) OCEAN 40 + EVO 40-12V OCEAN 40 + EVO 40-24V Cutout (500 kg) Cutout (500 kg) (A) Line Speed (m/min) (B) Current (Amp) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) (C) Load (kg) OCEAN 46 + EVO 45-12V OCEAN 46 + EVO 45-24V Cutout (800 kg) Cutout (800 kg) (A) Line Speed (m/min) (B) Current (Amp) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) (C) Load (kg) OCEAN 48 + EVO 50-12V & 24V OCEAN 50-12V & 24V Cutout (1000 kg) Cutout (1250 kg) (A) Line Speed (m/min) (B) Current (Amp) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) (C) Load (kg) 18

19 OCEAN 54 + EVO 55-12V & 24V OCEAN 58-12V & 24V Cutout (1350 kg) Cutout (1450 kg) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) OCEAN 65 + EVO 65-12V & 24V Cutout (1580 kg) Cutout (1814 kg) (A) Line Speed (m/min) (B) Current (Amp) (A) Line Speed (m/min) (B) Current (Amp) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) OCEAN 68/3 + EVO 70-24V (C) Load (kg) (C) Load (kg) OCEAN 77/3 + EVO 80-24V Cutout (2721 kg) (A) Line Speed (m/min) (B) Current (Amp) (C) Load (kg) Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 19

20 GB 6.4 Hydraulic performance The following graphs show line speed and load characteristics against hydraulic flow and pressure. The following graphs show the maximum performance envelope. Refer to trouble shooting (section 9) if performance is inferior. (A) Load / (B) Pressure / (C) Line Speed / (D) Flow Safe Working Loads (SWL) for hydraulic winches are lower than hand controlled winches due to significantly higher input/torque. If winch models are installed with an Autoshift Commander unit, only one deck switch may be required. Winch models EVO are single switch operation only. Refer to Commander manual for deck switch installation details. OCEAN 46 + EVO 45 (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 48 + EVO 50 (lbs) (kg) (ft/min) (m/min) (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 50 (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) 20

21 OCEAN 54 + EVO 55 (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 58 (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 65 + EVO 65 (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 21

22 GB OCEAN 68 + EVO 70 (lbs) (kg) (ft/min) (m/min) (A) Load (C) Line Speed (ft/min) (m/min) (A) Load (C) Line Speed (A) Load (C) Line Speed (A) Load (C) Line Speed (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 77 + EVO 80 (lbs) (kg) (ft/min) (m/min) (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 88 (lbs) (kg) (105 bar) (ft/min) (m/min) (25 l/min) (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min) OCEAN 111 (lbs) (kg) (bar) (l/min) (B) Pressure (psi) (D) Flow (gal/min 22

23 7- Servicing 7.1 Parts list Electric NOTE: Manual winches cannot be converted into electric versions by adding parts listed here. * EVO part only. All other parts are common to both models OCEAN EVO # DESCRIPTION QTY 1 Centre Stem * Centre Stem Gear Spindle Rachet Pawl Gear Pawl Spring /7 1260/7 1260/7 1260/7 1260/7 1260/7 1260/7 5 Bearing Drive Shaft Key Plain Bearing Base Plate Cover * Base Plate Cover Base Plate Dowel Shaft Seal 1 B6234 B6234 B6234 B6235 B6235 B6235 B Insulation Shim HEX Bolt M8x25 4 B0173 B0173 B0173 B0173 B0173 B0173 B Washer M8 4 B1207 B1207 B1207 B1207 B1207 B1207 B Plate CSK HD screw M6 x 12 5 B0678 B0678 B0678 B0678 B0678 B0678 B0678 CSK HD screw M6 x 16 5 B CSK HD screw M8 x B0536 B CSK HD screw M8 x B0812 B CSK HD screw M10 x B0567 B0567 Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 23

24 GB 7.2 Parts list Hydraulic * EVO part only. All other parts are common to both models OCEAN EVO # DESCRIPTION QTY 1 Centre Stem * Centre Stem Gear Spindle Rachet Pawl Gear Pawl Spring /7 1260/7 1260/7 1260/7 1260/7 1260/7 5 Bearing Drive Shaft Plain Bearing Base Plate Cover * Base Plate Cover Base Plate Dowel Shaft Seal 1 B6234 B6234 B6235 B6235 B6235 B Insulation Shim Plate Washer M12 B1212 B1212 B1212 B1212 B1212 B HEX Bolt M12 4 B0061 B0061 B0061 B0061 B0061 B Hydraulic motor 4 B7718 B7719 B7719 B7720 B7720 B CSK HD Screw M6 x 12 1 B0678 B0678 B0678 B0678 B0678 B0678 CSK HD screw M8 x 16 6 B0536 B CSK HD screw M8 x B0812 B CSK HD screw M10 x B0567 B

25 7.3 Parts list Electric *2 Speed versions shown/detailed. * EVO part only. All other parts are common to both models OCEAN 68-*2 77-*2 EVO 70/2 80/2 # DESCRIPTION QTY 1 Push Rod Assembly * Push Rod Assembly Spring O Ring 1 B2532 B Bush Spring Clip 1 B9941 B Drive Dog Seal 1 B2593 B Thrust Sleeve Spring Hollow Dowel Bush Screw 4 B0686 B0686 Heli-coil 4 B2423 B Roller Bearing Thrust Washer Connecting Shaft Adaptor Key Motor/Gearbox 12 V Motor/Gearbox 24 V Power Base * Power Base Main Spindle * Main Spindle Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 25

26 GB 7.4 Parts list hydraulic Adaptors not required on 68 and 77 * EVO part only. All other parts are common to both models a

27 OCEAN & EVO 70 70/3 - - # DESCRIPTION QTY 1 Push Rod Assembly * Push Rod Assembly Spring O Ring 1 B2532 B2532 B2532 B Bush Seal 1 B2593 B2593 B2578 B Screw 4 B0686 B0686 B0687 B Drive Dog Spring Sleeve Adaptor Screw M12 2 B0061 B0061 B0061 B Thrust Washer Roller Bearing Roller Bearing Bush Thrust Sleeve Connecting Shaft Spring Clip Gasket Hollow Dowl Adaptor Plate SKT CAP HD M12 x B0688 B Washer M12 2 B1212 B1212 B1212 B Hollow Dowl Adaptor Base Alloy * Adaptor Base Alloy a Adaptor Base Chrome Hydraulic Motor Unit 1 B7717 B7717/B7718 B7719 B7720 Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 27

28 GB 7.5 General maintenance WARNING! Isolate the winch using circuit breaker/isolator when not in use. WARNING! Electric motors become hot during and for some time after use. For more comprehensive information on stripping and cleaning your winch refer to B2304 Manual - How to service your winch from Monthly Hose down winch with fresh water Remove drum, then lightly oil the pawls and grease the gears and bearings taking care not to get any grease in the pawls as they will stick in operation. Two or three times during active sailing season. Strip, clean, check and lubricate. End of season or beginning of new season. Strip, clean and thoroughly check for damage, lubricate and reassemble as detailed in B2304 Manual. Check condition of motor/gearbox. In the event of corrosion, clean and repaint motor with marine grade oil based enamel paint. 28

29 8- Specifications 8.1 Electric above/below deck dimensions L = Line entry. T = Extension kits to increase T are available to special order. OCEAN H - HEIGHT L - LINE ENTRY M P T U V B - BASE Ø mm in mm in mm in mm in mm in mm in mm in mm in / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /8 68/ / / / / / / / / / / / / / / / /16 77/ / / / / / / / / / / / / / / / / H - HEIGHT L - LINE ENTRY M P T U V B - BASE Ø EVO mm in mm in mm in mm in mm in mm in mm in mm in / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /8 70/ / / / / / / / / / / / / / / / /16 80/ / / / / / / / /16 B B H L H L T T U U M V M Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 29

30 GB 8.2 Hydraulic above/below deck dimensions L = Line entry. T = Extension kits to increase T are available to special order. OCEAN WINCH H - HEIGHT L - LINE ENTRY M N T R B - BASE Ø B - BASE Ø mm in mm in mm in mm in mm in mm in mm in mm in / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /8 68/ / / / / / / / / / / / / / /16 77/ / / / / / / / / / / / / / / / / EVO WINCH H - HEIGHT L - LINE ENTRY M N T R B - BASE Ø B - BASE Ø mm in mm in mm in mm in mm in mm in mm in mm in / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / /8 70/ / / / / / / / / / / / / / / / /16 80/ / / / / / / / / 16 B B L H L H T N R T R 30 M M

31 8.3 Electric OCEAN winch specifications 12V OCEAN WINCH ALLOY CHROME MOTOR/ GEARBOX MOTOR MAXIMUM WINCH LOAD ROPE DIAMETERS CIRCUIT BREAKER (NOT SUPPLIED) Watt kg lb Ø mm Ø inch / 16-1 / 2 90 A / 16-9 / A / 16-9 / A / 16-5 / A / 16-5 / 8 *200 A / / 16 *250 A / / 16 *250 A / 8-3 / A / / 8-3 / A / 2-7 / A / / 2-7 / A OCEAN WINCH ALLOY WEIGHT CHROME WEIGHT E CONTACTOR E CONTACTOR BOX ELS CONTROL BOX (T 1-8) N/A (T 2-2) N/A (T 2-3) N/A N/A (T 1-7) N/A N/A (T 2-5) N/A N/A (T 2-7) N/A N/A (T 2-7) N/A N/A / N/A N/A N/A N/A / N/A N/A *ANL Fuse alternative available - contact Lewmar. NOTE: Maximum safe working loads are recommended to be not more than those detailed above. This provides an acceptable safety margin for dynamic load surges in extreme sea conditions. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 31

32 GB 8.4 Electric EVO winch specifications 12V EVO WINCH ALLOY CHROME MOTOR/ GEARBOX MOTOR MAXIMUM WINCH LOAD ROPE DIAMETERS CIRCUIT BREAKER (NOT SUPPLIED) Watt kg lb Ø mm Ø inch /16-1/2 90 A /16-1/2 90 A /16-9/ A /16-9/ A /16-9/ A /16-9/ A /16-5/8 *200 A /16-11/16 *250 A /8-3/4 120 A / /8-3/4 120 A /2-7/8 150 A / /2-7/8 150 A EVO WINCH ALLOY WEIGHT CHROME WEIGHT E CONTACTOR E CONTACTOR BOX ELS CONTROL BOX (T 1-8) N/A (T 2-2) N/A (T 2-3) N/A N/A (T 2-5) N/A N/A (T 2-7) N/A N/A / N/A N/A N/A N/A / N/A N/A * ANL Fuse alternative available - contact Lewmar. Motor/gearbox with pre-mounted E Series Contactor. NOTE: Maximum safe working loads are recommended to be not more than those detailed above. This provides an acceptable safety margin for dynamic load surges in extreme sea conditions. 32

33 8.5 Electric OCEAN winch specifications 24V OCEAN WINCH ALLOY CHROME MOTOR/ GEARBOX MOTOR MAXIMUM WINCH LOAD ROPE DIAMETERS CIRCUIT BREAKER (NOT SUPPLIED) Watt kg lb Ø mm Ø inch /16-1/2 40 A /16-9/16 50 A /16-9/16 70 A /16-5/8 90 A /16-5/8 90 A /16-11/16 90 A /16-11/16 90 A OCEAN WINCH ALLOY WEIGHT CHROME WEIGHT E CONTACTOR E CONTACTOR BOX ELS CONTROL BOX (T 1-3) (T 1-6) N/A (T 1-7) N/A N/A (T 2-3) N/A N/A (T 1-7) N/A N/A (T 1-8) N/A N/A (T 1-8) NOTE: Maximum safe working loads are recommended to be not more than those detailed above. This provides an acceptable safety margin for dynamic load surges in extreme sea conditions. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 33

34 GB 8.6 Electric EVO winch specifications 24V EVO WINCH ALLOY CHROME MOTOR/ GEARBOX MOTOR MAXIMUM WINCH LOAD ROPE DIAMETERS CIRCUIT BREAKER (NOT SUPPLIED) Watt kg lb Ø mm Ø inch /16-1/2 40 A /16-1/2 90 A /16-9/16 50 A /16-9/ A /16-9/16 70 A /16-9/ A /16-5/8 90 A /16-11/16 90 A /8-3/4 70 A / /8-3/4 70 A /2-7/8 70 A / /2-7/8 70 A EVO WINCH ALLOY WEIGHT CHROME WEIGHT E CONTACTOR E CONTACTOR BOX ELS CONTROL BOX (T 1-3) (T 1-6) N/A (T 1-7) N/A N/A (T 1-7) N/A N/A (T 1-8) N/A N/A / N/A N/A N/A N/A / N/A N/A Motor/gearbox with pre-mounted E Series Contactor. NOTE: Maximum safe working loads are recommended to be not more than those detailed above. This provides an acceptable safety margin for dynamic load surges in extreme sea conditions. 34

35 8.7 Hydraulic OCEAN winch specifications OCEAN WINCH SIZE ALLOY CHROME ST/STEEL HYDRAULIC DRIVE UNIT SAFE WORKING LOAD (SWL) ROPE DIAMETERS ALLOY WEIGHT CHROME WEIGHT kg lb Ø mm Ø inch kg lb kg lb B /16-9/ B /16-9/ B /16-5/ B /16-5/ B /16-11/ B /16-11/ B /8-3/ / B /8-3/ B /2-7/ / B /2-7/ B / / B / B /8-11/ / B /8-11/ Hydraulic EVO winch specifications EVO WINCH SIZE ALLOY GREY CHROME ALLOY BLACK HYDRAULIC DRIVE UNIT SAFE WORKING LOAD (SWL) ROPE DIAMETERS ALLOY WEIGHT CHROME WEIGHT kg lb Ø mm Ø inch kg lb kg lb B / 16-9 / B / 16-9 / B / 16-5 / B / / B / 8-3 / / B / 8-3 / B / 2-7 / / B / 2-7 / NOTE: Maximum safe working loads are recommended to be not more than those detailed above. This provides an acceptable safety margin for dynamic load surges in extreme sea conditions. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 35

36 GB 9- Trouble shooting 9.1 Electric question & answer Winch will not operate manually Check for correct assembly. Pawls stuck-over use of grease Strip and clean as necessary Winch will not operate electrically 1. Is winch handle locked in (Models only). Remove handle Check drive dog and spring, ensure free operation 2. Power at the battery. Check terminal connections, battery voltage - adequate reserve battery capacity. 3. Isolator switch/circuit breaker on. Switch on 4. Check fuse in control box. Change fuse (3 Amp), check wiring 5. Power at winch. Check circuit diagram, connections, clean and check cables 6. Check switch connection in control box. Reconnect Motor runs but winch does not turn Check polarity. 9.2 Hydraulic oil leakage The following are possible causes for hydraulic oil leakage from hydraulic drive unit: Excessive pressure. Dirt obstructing a seal. Loose or badly fitted connections. Damaged or broken components. When an hydraulic oil leak is detected, identify the true cause of the leakage before remedial action is taken. WARNING! Do not attempt to remove hydraulic components or repair the hydraulic system whilst pressured. To prevent accidental operation, switch off power before removing any system component. 36

37 9.3 Hydraulic question & answer Winch will not start 1. No power to Commander Check unit is switched on Check electrical connections to Commander Check fuses & safety cut-outs 2. Insufficient hydraulic fluid Check Commander fluid level. 3. Incorrect electrical or hydraulic connections Refer to your Lewmar Commander manual See the button sheet for correct function identification. Winch motor is running but the winch is not working Winches Hydraulic pipes connected the wrong motor port. Swap the hydraulic connections on the winch motor. Winches Winch handle left in winch Remove handle. 3. Mechanical fault Check all pawls & springs for correct operation and engagement. Check drive dog & spring Ensure free operation and engagement. Winch runs very slowly 1. Hydraulic pipes connected to wrong Commander function. Refer to Commander manual and examine the button sheet to identify correct function. 2. Hydraulic pipes connected to the wrong motor port. Swap hydraulic connections on the winch motor. 3. Deck switch connected to wrong function. Refer to Lewmar Commander manual. Winch does not pull sufficient load 1. Insufficient hydraulic fluid. Check Commander fluid level. 2. Hydraulic pipes connected to wrong Commander function. Refer to Commander manual. Examine the Button Sheet to identify correct function. 3. Sharp bends or kinks in the hydraulic pipes starving the winch of fluid. Check pipe runs for sharp bends or kinks. Minimum bend radius is 6 (150mm). 4. System pressure too low. Refer to fault diagnostic charts in the Commander manual. Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 37

38 GB Notes 38

39 9. Warranty Limited Warranty and Key Terms of Supply by Lewmar Lewmar warrants that in normal private pleasure boat usage and with proper maintenance its products will conform with their specification for a period of three years from the date of purchase by the end user, subject to the conditions, limitations and exceptions listed below. Any product, which proves to be defective in normal usage during that three-year period, will be repaired or, at Lewmar s option, replaced by Lewmar. A CONDITIONS AND LIMITATIONS i Lewmar s liability shall be limited to the repair or replacement of any parts of the product which are defective in materials or workmanship. ii Responsibility for the selection of products appropriate for the use intended by the Buyer shall rest solely with the Buyer and Lewmar accepts no responsibility for any such selection. iii Lewmar shall not be liable in any way for Product failure, or any resulting loss or damage that arises from: a. use of a product in an application for which it was not designed or intended; b. corrosion, ultra violet degradation or wear and tear; c. a failure to service or maintain the product in accordance with Lewmar s recommendations; d. faulty or deficient installation of the product (unless conducted by Lewmar); e. any modification or alteration of the product; f. conditions that exceed the product s performance specifications or safe working loads. g. Abuse iv Product subject to a warranty claim must be returned to the Lewmar outlet that supplied the product for examination unless otherwise approved by Lewmar in writing. v This warranty does not cover any incidental costs incurred for the investigation, removal, carriage, transport or installation of product. vi Service by anyone other than authorized Lewmar representatives shall void this warranty unless it accords with Lewmar guidelines and standards of workmanship. vii Lewmar s products are intended for use only in the marine environment. Buyers intending to use them for any other purpose should seek independent professional advice as to their suitability. Lewmar accepts no liability arising from such other use. B EXCEPTIONS Cover under this Warranty is limited to a period of one year from the date of purchase by the end user in the case of any of the following products or parts of products: Electric motors and associated electrical equipment Electronic controls Hydraulic pumps, valves and actuators Hatch & Portlight weather seals Products used in Grand Prix racing applications Products used in commercial or charter applications Anchor rodes C LIABILITY i Lewmar s liability under this warranty shall be to the exclusion of all other warranties or liabilities (to the extent permitted by law). In particular (but without limitation): a. Lewmar shall not be liable for: Any loss of anticipated turnover or profit or indirect, consequential or economic loss; Damages, costs or expenses payable to any third party; Any damage to yachts or equipment; Death or personal Injury (unless caused by Lewmar s negligence). Some states and countries do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you b. Lewmar grants no other warranties regarding the fitness for purpose, use, nature or satisfactory quality of the products. ii Where applicable law does not permit a statutory or implied warranty to be excluded, then such warranty, if permitted by that state or country s law, shall be limited to a period of one year from the date of purchase by the end user. Some states and countries do not allow limitations on how long an implied warranty lasts, so this limitation may not apply to you. D PROCEDURE Notice of a claim for service under this warranty shall be made promptly and in writing by the end user to the Lewmar outlet that supplied the product or to Lewmar Limited at Southmoor Lane, Havant, Hampshire PO9 1JJ, England. E SEVERANCE CLAUSE If any clause of this warranty is held by any court or other competent authority to be invalid or unenforceable in whole or in part, the validity of the remaining clauses of this warranty and the remainder of the clause in question shall not be affected. F OTHER RIGHTS This warranty gives you specific legal rights, and you may also have other legal rights, which vary from state to state and country to country. In the case of European States a Consumer customer (as defined nationally) has legal rights under the applicable national law governing the sale of Consumer Goods; this Warranty does not affect those rights. G LAW This warranty shall be governed by and read in accordance with the laws of England or the state or country in which the first end user is domiciled at the time of purchase of the product. H DISPUTES Any dispute arising under this warranty may, at the option of the end-user, be referred to alternative dispute resolution under the rules of the British Marine Federation or to the Courts of the State whose law shall govern the warranty or to the Courts of England and Wales. The British Marine Federation may be contacted at Marine House, Thorpe Lea Road, Egham, England, TW20 8BF Lewmar OCEAN & EVO Electric/Hydraulic Winches ref B2303 Iss.12 39